Reconstruction side window Lamborghini 400GT 2+2

Many pitfalls lurk in the course of restoring classic cars. In addition to the usual difficulties with the supply of spare parts, there are also mishaps here and there. During the restoration of this rare Lamborghini 400GT, the side window of the driver’s door was broken.

For a vehicle from the 60s, of which there are estimated to be only a few hundred left, it is of course a big problem to find a replacement. The only remedy is a professional reconstruction.

For this purpose, the passenger side window was removed and coated with a special, removable lacquer to ensure an optical 3D scan. With the help of the scan system, the pane is circled several times from all angles in order to record the entire shape.

The result is a point cloud consisting of over 2 million individual points, so-called facets. This now serves as a template for the creation of the 3D model.

This point cloud is then decimated and reduced to approx. 50,000 facets in order to process the data in the CAD programme. In the CAD software, a mesh is created by the experienced designer, which is placed over the point cloud. Afterwards, the surfaces can be smoothed, edited and improved. Once the final 3D model has been created, the component can be transferred to production.

For large spare parts with lengths of more than one metre, stereolithography, or SLA for short, is a suitable process. With this method, even large spare parts can be reproduced without any problems. Various resins are used as raw material, which are cured layer by layer with a UV laser. Another advantage is the very smooth surface that can be achieved with this process.

The stability of the component also meets the requirements and the so-called “master model” for the glass manufacturer is completed. He uses the 3D-printed model for the mould construction and finally for the adjustment of the dimensions on the outside of the finished pane. Of course, the dimensional accuracy was confirmed beforehand by a test installation on the vehicle. The result is impressive.

Now nothing stands in the way of the new windscreen and a happy vehicle owner emerges from a lengthy process. For this rare vehicle, the effort was worth it in any case, we think.

Please also visit our other articles on the subject of 3D printing and reconstruction for vintage and classic cars or send us an online enquiry!